HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990)

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

ENGINE COMPRESSOR WATER WASH KIT

INITIAL INSTALLATION

1. Engine Compressor Water Wash Kit Initial

(4).

Drill or cut 0.4531 inch (11.50874 mm)

Installation

hole in firewall assembly at dimension

shown in view A-A. Position and install

A. Gaining Access to Work Area

AN848-4D hose elbow in firewall with

hardware as shown.

(1). In aft compartment, remove seat

assemblies, L/H bulkhead trim, access

(5).

Cut hole for MS35489-11 grommet in

cover and insulation; gearbox access

forward wall of plenum chamber per

cover.

dimensions shown; install grommet

with sealant (CM430).

(2). Remove engine air inlet forward

fairing; open plenum chamber access

(6).

Position 369H3042 spray assembly on

door.

inner side of plenum chamber forward

wall, view B-B, with tube inserted

Install temporary cover of card

forward through grommet. Mark and

CAUTION

board or suitable material over

drill rivet holes and install spray

engine air intake.

assembly with eight NAS1738M4-2

rivets. Install rivets with primer.

(3). Remove engine air shield screen or

engine air inlet screen, as applicable;

(7).

Install 369H3048-5 hose on spray

remove access cover from mast support

assembly tube and on hose elbow at

structure panel.

firewall; secure hose at each end with

AN737TW22 clamps.

(4). Open L/H engine compartment door.

(8).

Mark and drill No. 8 hole in 369H3024

B. Airframe Modification and Installation

channel and install MS25281-4 clamp

and hardware as shown. Secure -5 hose

(Ref. Figure 901)

with clamp.

(9).

Install 369H3048-3 hose on elbow at

Consumable Materials

left side of firewall and on hose adapter

(Ref. Section 91−00−00)

at forward side of lower section ring.

Item

Nomenclature

Secure hose at each end with

CM318

Primer

AN737TW22 clamps.

CM430

Sealant, solvent resistant

2. Installation Inspection

(1). Position 369H3047 support on Sta.

(1). Carefully check and/or vacuum the

137.50 lower section ring at dimensions

plenum chamber for any foreign objects

shown in view E-E. Mark and drill

or debris. Remove protective cover from

rivet holes and install support with six

engine air intake.

NAS1398B4-2 rivets. Install rivets

with Primer (CM318).

NOTE: Spray kit using 369H3042 nozzle re

quires 60 PSI (414 kPa) to establish water

(2). Drill No. 8 hole in ring assembly; locate

flow rate of one quart (0.946 L) in 9-10 sec

from existing hole in support.

onds. A bypass valve or equivalent installed

at source hose connection is recommended

(3). Install AN807-4D hose adapter in

in order to relieve pressure and facilitate

support with hardware as shown;

disconnection at hose adapter.

install lanyard clip in hole with hard

ware as shown. Install 369H3046 cap

(2). Perform operational check of water

on hose adapter.

wash kit installation.

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MAINTENANCE MANUAL

(3). Reinstall removed components and

(4). Record installation of 369H92537

assemblies; install and secure access

engine compressor water wash kit in

covers and doors.

helicopter Log Book.

STA.

127.00

137.50

0.22 IN.

0.00

MS35489-11

(5.588 MM)

GROMMET (1 REQD)

TYPICAL

(DO NOT SPLIT)

0.76 IN.

(19.304 MM)

0.60 IN.

50.00

(15.24 MM)

0.38 IN.

(9.652 MM)

NOTE

C ENGINE

HOLE FOR

GROMMET

AN737TW22

CLAMP (2 REQD)

AN848-4D HOSE ELBOW

1.75 ±0.10 IN.

(44.45 ±2.54 MM)

AN960PD716L WASHER

369H3048-5 HOSE

AN924-4D NUT

369H3046 CAP AND

LANYARD ASSEMBLY

AN807-4D HOSE ADAPTER

AN960PD716L WASHER

AN924-4D NUT

AN737TW22 CLAMP

(2 REQD)

AFT SECTION ASSEMBLY

369H3048-3 HOSE

FUSELAGE STRUCTURE

AN737TW22 CLAMP

NOTE: SEAL WITH SILICONE SEALANT.

G71-1023-1A

Figure 901. Engine Compressor Water Wash Kit Installation (Sheet 1 of 3)

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CSP-HMI-2

MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

DESCRIPTION AND OPERATION

1. Description and Operation

Later installations feature a system of

clips that retain the mist eliminator in

(Ref. Figure 1)

sealed contact with the particle separa

tor. The mist eliminator consists of a

(1).

MDHI 369/500 helicopters may be

welded stainless steel frame and wire

equipped with an optional engine inlet

mesh screens on the fore and aft faces.

air particle separator filter installation

in place of the standard engine air inlet

(5).

Air drawn through the particle separa

screen.

tor by the engine passes through the

parallel vortex tubes. Each tube is

(2).

Later model helicopters are equipped

fitted with vanes and an opening to the

with a Aircraft Porous Media (APM)

particle collection chamber. The vanes

filter. Earlier 500D helicopters were

spin the incoming air so that centrifu

fitted with a Donaldson particle

gal force separates heavier solid bits

separator. The APM unit is equipped

from the air flow. A smaller diameter

with provisions for an optional mist

tube directs particle free center vortex

eliminator installation.

tube air through the collection chamber

rear plate into the plenum chamber.

(3).

Both the APM and Donaldson particle

When the scavenge air system is

separators are installed inside the front

switched ON, trapped particles are

of the aft intake fairing above the

drawn out of the collection chamber by

plenum chamber and utilize the same

scavenge air vacuum and discharged

operating principle. The particle

overboard through an opening in the

separator installation consists of vortex

right side of the aft inlet fairing of APM

tubes, a collection chamber, a nozzle

equipped helicopters and the left side

manifold, ejectors, flapper valve, seals

on Donaldson equipped machines. The

and attaching hardware. A scavenge air

nozzle manifold is fitted with an engine

system is used to remove trapped

bleed air inlet port and air jets to

particles from the collection chamber

discharge contaminants. The ejector

with engine bleed air. The scavenge air

assembly consists of a mounting flange

system consists of a solenoid air valve,

with tubes, duct assembly and flapper

tubes, an air pressure switch, SCAV

valve.

AIR circuit breaker switch, AIR

FILTER CLOGGED caution light,

(6).

The scavenge air system is supplied

wiring, and attaching hardware. An air

compressor bleed air controlled by the

bypass door system is included to allow

solenoid air valve. Bleed air is delivered

the particle separator to be bypassed in

to a duct-mounted nozzle-manifold

the event the unit becomes clogged. The

that ejects contaminants from the

air bypass door system includes a

particle separator. The electrically

hinged plenum chamber door, door

actuated solenoid air valve is mounted

latches, door actuating forward and aft

on the left forward side of the Station

cables, cable return spring, two retain

124.00 bulkhead. The valve is con

ers, three cable pulleys, adjustable

trolled by the SCAV AIR circuit breaker

cable stop, handle and attaching

switch on the instrument panel.

hardware.

(7).

An increase in plenum chamber

(4).

An optional mist eliminator may be

vacuum (reduced plenum chamber

fitted to the back of APM separators to

pressure) caused by reduced airflow

filter liquid sprays out of engine inlet

through a clogged filter/mist eliminator

air. Nine self retaining bolts secure

is sensed by a differential pressure

early mist eliminator installations to

switch ported to the plenum chamber

the aft face of the particle separator.

and particle separator inlet. Sufficient

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MD Helicopters, Inc.

MAINTENANCE MANUAL

pressure differential causes the switch

retainers on the aft end of the forward

to close. Switch closure lights an AIR

cable returns the handle to the stowed

FILTER CLOGGED caution indicator

position. An adjustable stop provides

on the instrument panel. A cable

for cable travel adjustment and air

actuated filter bypass door on the

bypass door rigging.

plenum chamber wall may be opened by

the pilot to allow the engine to operate

On 500N installation, the FILTER

on unfiltered air.

BYPASS CONTROL handle in the crew

(8). Pulling the FILTER BYPASS CON

compartment disengages one door latch

TROL handle in the crew compartment

inside the air inlet aft fairing and opens

disengages two door latches inside the

the door inward. Adjustment of this

engine air inlet aft fairing and opens

cable installation is limited by reposi

the door inward. A spring and two

tioning the cable assembly.

Table 1. Engine Air Particle Separator Configurations

Model Part Number Cabin Heat

Principal Features

500N

500N90148−3

APM filter with new pressure switch and T−pedestal electrical

500N90148−1

Yes

installation.

530FF

369H90148−543

APM filter with generic wire harness and no cabin heat

369H90148−541

Yes

APM filter with generic wire harness and cabin heat

369H90148−529

APM filter with new pressure switch and T−pedestal electrical

369H90148−527

Yes

installation.

500E

369H90148−545

Yes

APM filter for C20R engine with generic wire harness

369H90148−539

APM filter for C20R engine with generic wire harness

369H90148−537

APM filter for C20B engine with generic wire harness

369H90148−535

Yes

APM filter for C20B engine with generic wire harness

369H90148−521

APM filter with T−pedestal electrical installation.

369H90148−519

Yes

500D

369H90148−509

APM filter with electrical controls bracket on side of slimline pedestal.

369H90148−507

Yes

369H90148−505

Donaldson filter with electrical controls bracket on side of slimline

369H90148−503

Yes

pedestal. No mist eliminator option.

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

FAULT ISOLATION

1. Engine Air Particle Separator Fault

Isolation

Table 101. Engine Air Particle Separator Fault Isolation

Symptom

Probable Trouble

Corrective Action

Turbine outlet temperature (TOT)

Partially blocked particle separator

Clean and service particle separator

gage indicates a moderate

and, or mist eliminator.

installation.

temperature increase with all other

indications normal.

FILTER CLOGGED caution light

Clogged filter.

Clean and service particle separator

on. Light goes out when air bypass

installation.

door is opened.

Filter requires frequent cleaning.

Inadequate scavenge air flow;

Inspect scavenge air system for

Loads up with SCAV AIR, ON and

leaking scavenge air bleed air

leakage. Repair system as required.

functioning.

lines.

Solenoid air valve blocked.

Clean solenoid air valve.

FILTER CLOGGED caution light

Lamp failed.

Replace lamp.

fails to come on when filter is

Disconnected, open or loose

Check continuity, repair or replace

clogged.

wiring.

Faulty air pressure switch.

Replace pressure switch.

FILTER CLOGGED caution light

Defective light assembly.

Replace light assembly.

stays on regardless of bypass door

Defective air pressure switch.

Replace air pressure switch.

position.

Wiring problem.

Repair wiring.

FILTER CLOGGED caution light

Defective wiring.

Repair wiring.

fails to come on when air filter is

Defective air pressure switch.

Replace air pressure switch.

clogged but works when tested.

FILTER BYPASS CONTROL

Disconnected or broken cable.

Repair or replace cables.

handle is pulled but bypass door

fails to open.

Air bypass door does not open all

Cable stop out of adjustment.

Adjust cable stop.

the way when FILTER BYPASS

CONTROL handle is pulled to

forward limit.

FILTER BYPASS CONTROL

Defective return spring.

Replace return spring.

handle fails to return to full aft

Cable kinked, worn or binding.

Repair or replace cable assembly.

position after control actuation.

No air is exhausted through outlet

Defective wiring.

Repair wiring.

duct with SCAV AIR circuit breaker

Disconnected or damaged

Connect or replace scavenge air line.

ON and engine running.

scavenge air line.

Defective solenoid air valve.

Replace solenoid air valve.

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CSP-HMI-2

MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

MAINTENANCE PRACTICES

1. Air Bypass Door System Maintenance

2. Solenoid Air Valve Cleaning

Consumable Materials

(Ref. Section 91−00−00)

Item

Nomenclature

Item

Nomenclature

CM112

Anti-seize compound high temperature

CM106

Fluorocarbon dry lubricant

NOTE: Maintain scavenge air equipment per

CAUTION

FAA publication, EA-AC43.13-1A and 2A.

D Prevent engine FOD. Secure a cover over

Use anti-seize compound

CAUTION

the engine intake prior to working inside

(CM112) on all male threaded

plenum chamber. Remove cover after

fittings prior to installation.

completing work.

(1). To access solenoid air valve; remove

D Loose, missing or improperly installed air

lower and center air duct trim from

bypass door hardware may cause engine

forward left side of aft passenger

damage.

compartment bulkhead.

NOTE: Maintain door system equipment per

NOTE: Solenoid air valve water flush proce

FAA publication, EA-AC43.13-1A and 2A.

dure may be accomplished with valve in

stalled or removed from helicopter. In either

(1).

Disconnect cable from door.

case, a 28 Vdc power supply is required to

actuate valve for cleaning.

(2).

Inspect and replace loose or worn door

(2). Connect a low pressure, clean water

hinge pins with 0.091 inch (2.3114 mm)

source to valve inlet fitting. Connect a

diameter corrosion resistant wire.

hose to the outlet fitting to route

(3).

Inspect all door hardware for wear,

discharged water to a drain. Connect a

corrosion, correct installation, secure

28 Vdc external power source to

attachment and proper operation.

helicopter or the valve, as required.

(3). Turn on water. Alternately open and

(4).

Connect cable to door.

close valve with SCAV AIR circuit

breaker switch to flush valve poppet

(5).

Close door. Check for positive latching

seat.

and correct alignment. Peel or add latch

clip shims to align door flush with

(4). Reverse air valve water connections.

fairing surface.

Repeat flushing procedure.

(6).

Rig air bypass door (Ref. Air Bypass

Compressor bleed air is hot

CAUTION

Door Rigging) after replacing either

enough to char tube identifica

forward or aft cable, or changing cable

tion tapes that may cause FOD. Remove

travel.

identification tapes from compressor bleed

air tubes prior to installation.

(7).

Spray gasket and door edge with S-122

fluorocarbon dry lubricant (CM106) if

(5). Install solenoid air valve. Torque valve

operating in temperatures below 40°F

mounting bolts to 22 - 27 inch-

(4.5°C).

pounds (2.49 - 3.05 Nm). Torque tube

nuts to 110 - 130 inch-pounds (12.43

(8).

Remove engine intake cover.

- 14.69 Nm).

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MAINTENANCE MANUAL

3. Air Pressure Sensing Switch Maintenance

(b). Have an assistant press hard against

the air bypass door in an attempt to

Air pressure switch and AIR FILTER

keep the latch-bolts from moving up

CLOGGED caution light circuit function may

out of their clips.

be quick-checked as follows:

(c). Grasp FILTER BYPASS CONTROL

handle and slowly move it forward.

(1). Open air bypass door.

The distance the handle travels

before meeting the solid resistance of

Prevent engine FOD. Secure a

CAUTION

the latch-bolts gives an indication of

cover over the engine intake

cable slack and lost motion due to

prior to working inside plenum chamber.

wear.

Remove cover after completing work.

(4). Remove cable slack as follows:

(2). Attach a suitable length of 3/16 inch

(a). Break lockwire between door latch

(4.76 mm) ID hose to pressure switch

center crank threaded swivel fitting

nipple. Connect a vacuum source to the

and cable end fitting (Ref.

hose.

Figure 201, detail D). Remove

attaching hardware and swivel

(3). Connect 28 Vdc power to the helicopter.

fitting from door latch center crank.

(4). Apply vacuum to pressure switch. The

Thread swivel fitting up swaged

AIR FILTER CLOGGED caution light

cable terminal end 2 - 3 turns.

should come on. Release the vacuum

Reassemble all door hardware except

and the light should go out.

lockwire.

(b). Repeat previous steps as required

4. Air Bypass Door Rigging (369D/E/FF)

until slack is removed. Do not

preload cable.

Rig air bypass door installation after replacing

(c). Lockwire cable end fitting to door

forward or aft cables or when door operation or

latch center crank swivel fitting.

opening angle is incorrect. Rig door as follows:

(5). Adjust door opening angle as follows:

Prevent engine FOD. Secure a

CAUTION

(a). Thread cable-stop in or out of stop

cover over the engine intake

sleeve until top of cable-stop is 1.65

prior to working inside plenum chamber.

inches (4.19 cm) below cable swaged

Remove cover after completing work.

ball.

(1). Cycle air bypass door control handle

(b). Pull FILTER BYPASS CONTROL

and door mechanism several times to be

handle forward until aft cable

certain system does not bind at any

swaged ball bottoms in cable stop.

point. Isolate problem and repair a

Maintain cable tension to keep cable

binding cable or door latch system

ball against stop.

before continuing.

(c). Pull air bypass door outboard to

(2). With door open, make sure FILTER

maintain cable tension.

BYPASS CONTROL handle is returned

Avoid an erroneous cable adjust

full aft against cable housing and

CAUTION

ment. Maintain a constant cable

spring resistance is immediately felt as

ball contact with cable stop as stop is ad

handle is started forward.

justed.

(3). Determine if there is excess slack in the

(d). Adjust cable stop until air bypass

cable system as follows:

door opens to a minimum 45° angle

relative to fairing exterior surface.

(a). Close air bypass door. Try door to

Measure angle between door and

make sure latch-bolts are bottomed

fairing exterior surface at Sta. 136.00

in latch-clips.

(Ref. Figure 201, details G and H).

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MAINTENANCE MANUAL

(e).

Release FILTER BYPASS CONTROL

(2). Cycle air bypass door control handle

handle. Inspect handle for freedom of

and door mechanism several times to be

movement, full retraction and contact

certain system does not bind at any

with forward fitting.

point. Isolate problem and repair a

binding cable or door latch system

(f).

Close air bypass door.

before continuing.

(g).

Check that aft cable is tight and

(3). Minor repositioning of the cable

cable swaged ball rests against top of

assembly can be performed by loosening

cable-stop.

the installation hardware to reposition

the cable.

(h).

Inspect pulley alignment. All pulleys

must line up within 0.13 inch (3.302

6. Particle Separator Cleaning

mm).

Consumable Materials

(i).

Inspect cable for correct routing

(Ref. Section 91−00−00)

around pulleys. Rotate each pulley

Item

Nomenclature

90° to distribute wear.

CM226

Cleaning compound, alkaline waterbase

(j).

Peel cable-stop support bracket

laminated shim as required to center

(1). Submerge separator in a solution of

cable inside cable-stop to within

detergent soap (CM226) and water for

0.060 inch (1.524 mm).

at least 15 minutes. Clean screens and

(k).

Torque cable-stop jam-nut to 10 - 30

vortex tubes with a soft, long-bristle

inch-pounds (1.13 - 3.39 Nm).

brush.

(2). Flush with clean water. Drain and blow

(6). Check all components of FILTER

out ejector nozzle with dry, low pressure

BYPASS CONTROL system for correct

compressed air.

operation. Inspect all fasteners for

security.

7. Mist Eliminator Maintenance

Air Bypass Door Rigging (500N)

(1). Remove mist eliminator and clean with

solvent or steam.

(Ref. Figure 202)

NOTE: Mist eliminator is all stainless steel.

Prevent engine FOD. Secure a

The assembly will not be harmed by conven

CAUTION

cover over the engine intake

tional metal cleaning solutions.

prior to working inside plenum chamber.

Remove cover after completing work.

(2). Examine plenum chamber. A dust

accumulation indicates leakage which

(1). The bypass door cable length is deter

must be identified and eliminated.

mined on the initial installation.

(3). Spray 15 milliliters of engine oil on

NOTE: The control cable assembly shall actu

each face of the mist eliminator prior to

ate with one pound pull.

installation.

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MAINTENANCE MANUAL

CABLE

CLIP

LINK

GASKET

CENTER

CRANK

LATCH ASSY

LAMINATED SHIM

(NOTE 3)

CLIP

FILTER BYPASS DOOR - INSTALLATION

WASHER

BOLT

AFT FAIRING

NUT

CABLE STOP

(NOTE 2)

CABLE STOP

SLEEVE

TYPICAL LINKAGE - INSTALLATION

CABLE STOP

(4 PLCS)

BRACKET

SHIM

SLEEVE NUT

(NOTE 4)

NOTES:

PULLEYS TO BE IN ALIGNMENT WITHIN 0.13 IN. (3.302 MM).

CABLE STOP JAMNUT

TIGHTEN NUT TO GET 0.005-0.015 IN. (0.127-0.381 MM) GAP BETWEEN

BOLT HEAD AND WASHER; 4 PLACES.

ADJUST LAMINATED SHIM THICKNESS TO GET CORRECT DOOR

LATCHING AND ALIGNMENT.

CABLE STOP - INSTALLATION

G71-1003-2B

Figure 201. Air Bypass Door System (369D/E/FF) (Sheet 2 of 3)

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MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

REMOVAL/INSTALLATION

1. PLM Particle Separator Replacement

(14). Disconnect and remove ejector scavenge

air line between particle separator and

A. PLM Particle Separator Removal

bracket mounted elbow.

(1). Remove forward engine air inlet

(15). If installed, remove mist eliminator.

fairings.

(16). Unbolt, then tilt top of particle separa

tor forward and remove from fairing.

(2). Pull FILTER BYPASS CONTROL

handle to open filter bypass door.

B. PLM Particle Separator Installation

Prevent engine FOD. Secure a

Install particle separator in reverse order of

CAUTION

cover over the engine intake

removal and per the following procedures:

prior to working inside plenum chamber.

Remove cover after completing work.

Consumable Materials

(Ref. Section 91−00−00)

(3). Remove engine air cooling inlet screen.

Item

Nomenclature

(4). In crew compartment; remove map case

CM112

Anti-seize compound high temperature

trim panel from control channel (Ref.

Chap. 25).

(1). Center and clamp tail rotor control

(5). Disconnect forward cable from aft cable

pedals in neutral position. Install

at quick-disconnect fitting. Remove

forward boot on tail rotor pitch control

spring retainers and spring.

rod. Adjust boot free length between

7.13 and 7.22 inches (18.1102 and

(6). Remove handle plug button. Separate

18.3388 cm). Install ty-rap.

retainers and remove handle.

(2). Use the same number of washers under

(7). Remove attaching hardware and cable

forward cable fitting as were removed.

retaining clamps. Remove cable forward

Washer stack height variances will

fitting nut and washers.

affect door rigging.

Use anti-seize compound on all

(8). Pull cable assembly forward into crew

CAUTION

male threaded fittings prior to

compartment far enough to clear

installation.

particle separator.

(3). Apply anti-seize compound (CM112) to

(9). Disconnect and remove pressure switch

fitting threads and particle separator

tubes, jam-nut, washers and union.

attaching hardware.

(10). Remove particle separator fairing

(4). Check air bypass door rig (Ref. Air

retaining screws and washers.

Bypass Door Rigging).

NOTE: Left fairing installations without re

(5). Perform an operational check of air

movable lower cover require the tail rotor

bypass door and scavenge air systems

control rod be disconnected at Sta. 95.00

(Ref. Scavenge Air Operational Check).

bellcrank to remove fairing from helicopter.

2. PLM Scavenge Ejector Replacement

(11). Remove tail rotor control rod boot

A. PLM Scavenge Ejector Removal

forward clamp.

(1). Remove lockwire and unbolt ejector

(12). Slide boot and left fairing forward and

assembly support bracket.

clear of particle separator.

(2). Remove lockwire and bolts attaching

(13). Unfasten and remove ejector duct

ejector assembly hold down plates to

assembly.

particle separator ejector box.

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MAINTENANCE MANUAL

(3). Remove ejector assembly.

B. Helicopters Without Mist Eliminator

Access Panel

B. PLM Scavenge Ejector Installation

Prevent engine FOD. Secure a

CAUTION

(1). Install ejector in reverse order of

cover over the engine intake

removal.

prior to working inside plenum chamber.

Remove cover after completing work.

3. PLM Ejector Nozzle and Manifold

(1). Pull FILTER BYPASS CONTROL

Replacement

handle to open air bypass door.

(1). Remove ejector assembly (Ref. PLM

(2). On 500N installation, remove the fan

Scavenge Ejector - Removal).

inlet screen and engine plenum access

fairing attachment hardware. Proceed

(2). Remove lockwire and two nuts securing

with step (5).

nozzle and manifold assembly to

particle separator ejector box.

(3). Remove four screws securing door hinge

upper halves to inlet fairing (Ref.

(3). Remove nozzle and manifold assembly.

Figure 201, detail D).

NOTE: Do not disturb established cable length.

(4). Clean mating surfaces between ejector

box and nozzle and manifold assembly.

(4). Remove cotter pin, nut and washer

from cable end-fitting. Remove cable

(5). Install nozzle and manifold assembly in

from door. Remove door.

reverse order of removal.

Nine mount bolts are retained

CAUTION

(6). Install ejector assembly.

in mist eliminator frame. Do not

attempt to remove bolts from frame.

4. Mist Eliminator Replacement

(5). Unbolt mist eliminator from particle

separator.

A. Helicopters With Mist Eliminator Access

Panel

(6). Pull mist eliminator aft to clear particle

separator frame. Tilt mist eliminator

CAUTION

lower edge up and remove unit through

bypass door opening.

D Prevent engine FOD. Secure a cover over

C. Mist Eliminator Installation

the engine intake prior to working inside

plenum chamber. Remove cover after

(1). Install mist eliminator in reverse order

completing work.

of removal.

D If mist eliminator is NOT to be rein

5. Donaldson Particle Separator

stalled, remove 4504 tape from particle

Replacement

separator. If not removed, tape may come

loose and be ingested by the engine.

A. Donaldson Particle Separator Removal

NOTE: Mist eliminator access panel installa

(1). Remove engine air inlet forward

tion replaces nine mist eliminator mount

fairings.

bolts with a system of permanently installed

(2). Pull FILTER BYPASS CONTROL

clips to secure mist eliminator.

handle to open the air bypass door (Ref.

Figure 201, detail A).

(1). On top of aft inlet fairing; unfasten two

1/4-turn panel fasteners. Lift panel

Prevent engine FOD. Secure a

trailing edge, then entire panel clear of

CAUTION

cover over the engine intake

access opening.

prior to working inside plenum chamber.

Remove cover after completing work.

(2). Lift mist eliminator out of access panel

opening.

(3). Remove engine air cooling inlet screen.

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(4). In crew compartment; remove map case

(15). Remove exit port screen attaching

trim panel from control channel (Ref.

hardware and duct.

Chap. 25).

B. Donaldson Particle Separator Installation

(5). Disconnect forward cable from aft cable

Install particle separator assembly in reverse

at quick-disconnect fitting. Remove

order of removal and as follows:

handle plug button. Separate retainers

and remove handle.

Consumable Materials

(6). Remove spring retainers and spring.

(Ref. Section 91−00−00)

Item

Nomenclature

(7). Remove attaching hardware and cable

CM112

Anti-seize compound high temperature

retaining clamps. Remove cable forward

fitting nut and washers. Pull cable

assembly into crew compartment.

NOTE: Apply antiseize compound (CM112) to

male threads of fittings, nozzle manifold

(8). Remove pressure switch tubes and

bolts and particle separator attaching hard

union.

ware before installation.

NOTE: It is not necessary to disconnect tail ro

(1).

Bench assemble rubber sleeve and

tor control rod to remove left fairing if fair

O-ring on grooved end of ejector.

ing is equipped with a removable cover.

(2).

Align nozzle manifold and ejector inside

(9). Disconnect forward end of tail rotor

aft fairing.

control rod at Sta. 95.00 bellcrank.

(3).

Position ejector so that top flapper

(10). Remove fairing retaining screws and

valve vertical hinge line angle is 10 to

washers. Remove tail rotor control rod

20 degrees counterclockwise from

boot forward.

ejector vertical centerline.

clamp. Slide left fairing forward on tail rotor

(4).

Torque ejector and nozzle manifold

control rod to clear particle separator.

bolts to 12 - 15 inch-pounds (1.36 -

1.69 Nm).

NOTE: Paint an alignment mark across ejector

and nozzle manifold flanges prior to disas

(5).

Install tail rotor control rod forward

sembly as a reference for later assembly.

boot with a free length of 7.13 to 7.22

inches (18.1102 and 18.3388 cm) with

(11). Remove bolts and washers securing

tail rotor pedals centered.

nozzle manifold to particle separator.

(6).

Use the same number of washers under

(12). Unbolt particle separator. Tilt top of

forward cable fitting as were removed.

particle separator forward and remove

Hardware position changes or washer

from fairing.

stack height variances will affect door

rigging.

(13). Disconnect upper air tube assembly

from nozzle manifold. Move forward

(7).

Rig air bypass door (Ref. Air Bypass

O-ring from ejector to rubber sleeve.

Door Rigging).

Remove nozzle manifold and ejector

(8).

Perform air bypass door and scavenge

from aft fairing.

air system operational checks (Ref.

(14). Remove sleeve and O-rings from duct.

Scavenge Air Operational Check).

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MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

INSPECTION/CHECK

1. Engine Air Inlet Bypass Door 300−Hour

(c). The latch engagement faying surface,

Inspection

where it contacts the plenum, is worn

more than 0.050 inch (1.270 mm)

(Ref. Figure 201)

below the original surface.

(5).

Inspect door hinges for wear and hinge

fastening hardware for security. Repair

Consumable Materials

or replace hinges as required.

(Ref. Section 91−00−00)

Item

Nomenclature

(6).

Inspect door for worn or damaged

latching and attachment hardware.

CM425

Sealing compound

(7).

Check insert assembly and latch

linkages for wear and lost motion.

Prevent engine FOD. Secure a

Repair or replace latch hardware as

CAUTION

cover over the engine intake

required.

prior to working inside plenum chamber.

(8).

Inspect door system cable and cable

Use extreme care when working around en

ends for corrosion, fraying, chaffing and

gine inlet to prevent any foreign object from

freedom of movement.

entering engine. Remove cover after com

pleting work.

(9).

Inspect door system cable pulleys,

pulley bushings and brackets for wear,

NOTE: Inspect Engine Air Inlet Bypass Door

damage, freedom of movement and

per FAA publication, EA-AC43.13-1B.

security.

(10).

Reinstall engine inlet bypass door. Seal

(1). Remove engine inlet bypass door and

all cotter pins with sealant (CM425).

inspect air bypass door gasket seal for

(11).

Inspect door for proper alignment when

condition and secure attachment. No

closed. Door must fit snug against seal

gasket seal deterioration or debonding

with obvious seal compression.

allowed. Replace door gasket as

required.

(12).

Inspect latches for positive latching.

(13).

Pull FILTER BYPASS CONTROL

(2). Inspect door surfaces for cracking,

handle. Action to be a smooth, positive

chaffing or damage. Repair door per

door opening with no binding. Release

Structural Repair Manual (CSP-

handle. Handle should snap back to

SRM-6).

stowed position.

(3). Remove and replace the latch retention

2. PLM Particle Separator Inspection

cotter pin (located inside the attach

(1). Inspect vortex generator tubes for

cable ``U'' clamp). Seal cotter pin with

broken, loose or missing vanes and

sealant (CM425).

center pins.

(4). Replace latch assembly if:

(2). Inspect outlet tube for security and

damage.

(a). The cotter pin hole in the latch stem

(3). Inspect inlet plate for dents punctures

is elongated more than 0.080 inch

and cracks.

(2.032 mm).

(4). Inspect vortex tube particle discharge

openings for clogging.

(b). The cotter pin has worn into the

surface of the cable attach ``U'' clip,

(5). Inspect separator and mist eliminator

more than 1/2 the thickness of the

mounting seals for secure attachment

clip, 0.025 inch (0.635 mm) deep.

and damage. Replace damaged seals.

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MAINTENANCE MANUAL

Left fairing inspection and re

(4). Inspect gasket tapes for deterioration

CAUTION

work or replacement is manda

and security. Replace damaged gasket

tory for particle separator installations, part

tapes.

numbers 369H90148-507, and -509. Early

(5). Inspect entire particle separator

installations were fitted with left forward

assembly for cracks, holes and distor

fairings, PN 369D290128-11 equipped with

tion. Cracks may indicate filter preload,

a single screw and nutplate securing a re

misalignment or distortion when

movable

fairing

section,

installed. Align filter (Ref. Particle

369D290128-31 over the tail rotor control

Separator Alignment and Joint Surface

rod.

Repair).

(6).

Inspect tail rotor control rod for

(6). Inspect rubber sleeves for cuts, holes or

abrasion or gouging caused by contact

deterioration.

with particle separator fairing or

fairing hardware. Modify, repair or

(7). Inspect O-rings for nicks, cuts, wear or

replace fairing (Ref Fairing Modifica

deterioration.

tion (369D Only)). Inspect, repair or

(8). Inspect ejector tube for cuts, breaks or

replace control rod if damaged beyond

distortion.

limits (Ref. Sec. 67-20-10).

(9). Inspect flapper valve for condition and

(7).

Inspect ejector flapper valve and hinge

free movement.

for wear and corrosion. Repair or

NOTE: Ejectors with a missing flapper valve

replace valve parts as required.

may be continued in operation until a re

placement is installed.

(8).

Inspect ejector tubes for cuts, breaks

and distortion. Inspect flange condition.

(10). Inspect nozzle manifold for cracks and

distortion.

(9).

Inspect tube nuts and fittings for

crossed or stripped threads.

(11). Inspect fitting for crossed or stripped

threads. See that the seven nozzle air

(10).

Inspect scavenge air discharge duct for

passages are open, clean and undam

damage.

aged.

(12). Inspect ejector exhaust duct screen for

(11).

Inspect entire assembly for cracks,

damage or clogging.

holes and distortion. Cracks may

indicate that assembly is subject to

4. Scavenge Air Operational Check

distortion loads when installed.

Engine operation or helicop

WARNING

3. Donaldson Particle Separator Inspection

ter flight must be accom

plished in accordance with require

(1). Inspect filter inlet screens for damage

ments and limitations specified in the

and secure attachment. Remove

Pilot's Flight Manual and applicable

damaged inlet screens.

supplements.

(1). Ensure air bypass door is closed.

NOTE: Particle separator may be operated

without inlet screens.

(2). Ground run engine per Pilot's Flight

Manual.

(2). Inspect vortex tubes for for security and

(3). Switch SCAV AIR circuit breaker ON.

broken or missing vanes.

NOTE: A slight increase in turbine outlet tem

NOTE: Up to five damaged vortex tubes may be

perature (TOT) is normal when SCAV AIR

blocked off with patches.

circuit breaker is switched ON.

(3). Inspect vortex tube particle separator

(4). Have an assistant check for scavenge

openings for clogging.

air exhaust from outlet duct. Airflow

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MAINTENANCE MANUAL

from duct indicates that solenoid air

the tube relative to the switch closing

valve has opened.

point. The total of the differential

heights of both legs of the u-tube is

(5). Switch SCAV AIR circuit breaker OFF.

equal to switch actuation pressure.

(6). Check that no scavenge air flows from

(6). Switch closing pressures shall be per

outlet duct.

the applicable particle separator

installation dash number shown (Ref.

(7). Shut down engine per Pilot's Flight

Figure 601).

Manual.

6. Mist Eliminator Inspection

Air Pressure Sensing Switch Calibration

Check

(1). Check mist eliminator serial number

for APM serial numbers 005 thru 069.

(1). Assemble test equipment (Ref.

Remove the wire staples from a mist

Figure 601).

eliminator so identified.

(2). Attach pressure switch to test equip

(2). Inspect frame and screens for security

ment. Connect a suitable vacuum

and condition. Replace mist eliminator

source to pressure switch nipple and

if screens are partially detached, or

u-tube.

assembly distortion prevents joint seal

(3). Connect an ohmmeter or continuity

contact with the particle separator.

tester to pressure switch electrical

(3). Inspect all nine bolts, where installed,

leads.

for security in mist eliminator frame.

(4). Cycle switch from open to close several

Repair or replace bolts as required (Ref.

times with vacuum. Watch meter for

Page 803).

indication of switch closure. Release

(4). Examine outlet side of mist eliminator.

vacuum.

Surface should be slightly oily but

(5). Slowly apply vacuum. Note u-tube

clean. Dirt on the outlet side signals the

water height differential in both legs of

need to clean the assembly.

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MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

REPAIRS

1. PLM Particle Separator Repairs

Permanent repairs or particle

CAUTION

separator replacement should

be accomplished as soon as possible. Do not

use repair kit if mounting plate holes are en

Consumable Materials

larged or distorted so as to prevent the re

(Ref. Section 91−00−00)

pair plug snap-lock lip from fully engaging

Item

Nomenclature

plate hole edge.

CM234

Solvent, dry-cleaning

(a). Repair plugs, AA-9500-D929 are

CM728

Tape, pressure sensitive

used to seal pushed-in but otherwise

undamaged vortex generator tubes.

(b). Stems, AA-9500-D930 are used with

NOTE:

repair plugs to seal the vortex

generator tube hole when the the

D The following particle separator repair/

tube is missing or removed.

replacement items and, or kits are avail

(c). Stems, AA-9500-D931 are used with

able from Pall Land Marine (PLM) or

repair plugs when both the vortex

through your local distributor (Ref. Sec.

generator tube and outlet tube are

01-00-00).

missing or removed.

D AA-A224-1D1KF1 Repair kit, Centrisep

No more than 30 of the 292

scavenge ejector Assy. (Ejector, two plate

WARNING

vortex generator tubes may

halves, four bolts).

be plugged. Plugged tubes shall be

widely distributed over particle sepa

D AA-224A-1D1KF2 Repair kit, Centrisep

rator. Not more than 15 plugged tubes

nozzle and manifold Assy.

may be concentrated in any one area.

B. Displaced Vortex Generator Tube

The following procedures are for

CAUTION

(Ref. Figure 801)

Pall Land Marine (PLM) par

ticle separators only.

(1). Inspect displaced vortex generator tube

for missing center pin and extensive

rim damage. Should either condition

A. Vortex Tube Plug Installation

exist, refer to Damaged Or Missing

Vortex Generator Tube.

NOTE: Procedures are per Pall Land Marine

(2). Position particle separator on a table

Corporation publication, PLM-TM-80-1.

with front surface of vortex tube plate

Contact PLM direct for additional informa

up.

tion. A vortex generator tube replacement

(3). Press damaged tube assembly all the

kit may be available that will supersede use

way in. Ensure that vortex tube

of Tube Repair Kit AA-8101-1KF1 required

bottoms on outlet tube per illustration

to accomplish the following temporary re

(Ref. Figure 801, view B).

pairs.

(4). Insert repair plug AA-9500-D929 in

the hole. Align plug with vortex

(1). The AA-8101-1KF1 repair kit contain

generator center pin.

parts required to plug holes created by

displacement of, or damage to, the

(5). Press plug into inlet tube plate until

vortex generator and outlet tubes.

plug snaps in place.

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C. Damaged Or Missing Vortex Generator

F. Fairing Modifications (369D Only)

Tube

(1). Remove remaining vortex generator

Consumable Materials

tube material without damaging plate

(Ref. Section 91−00−00)

hole.

Item

Nomenclature

CM501

Fiberglass cloth

(2). Insert center pin of stem

CM505

Polyester laminating resin

AA-9500-D930 into plug

AA-9500-D929 and install in hole per

illustration (Ref. Figure 801, view C).

NOTE: Modification procedures apply to 500D

Ensure stem free end is inside outlet

series helicopters equipped with

tube.

369H90148-507 or -509 particle separator

(3). Press plug into hole until it snaps in

installations and APM (now PLM) particle

place.

separators. Early installations were fitted

with left forward fairings, PN

D. Damaged Or Missing Vortex Generator

369D290128-11 equipped with a single

and Outlet Tubes

screw and nutplate securing a removable

fairing section, PN 369D290128-31 over the

(1). Remove remaining vortex generator

tail rotor control rod. Modify the -11 and

and outlet tube material. Do not

-31 fairing components as follows.

damage either plate hole.

(1). Remove fairings (Ref. PLM Particle

(2). Insert center pin of stem

Separator Removal).

AA-9500-D931 into plug

AA-9500-D929 and install in hole per

(2). Drill out rivets and remove nutplate

illustration (Ref. Figure 801, view D).

from 369D290128-11 left fairing

Ensure stem free end protrudes from

assembly (Ref. Figure 802, detail A).

outlet tube plate.

(3). Patch nutplate rivet and screw holes

(3). Press plug into hole until it snaps in

with fiberglass cloth (CM501) and resin

place.

(CM505) per structural repair manual

E. PLM Particle Separator Gasket

(SRM).

Replacement

NOTE: A replacement

cover,

(1). Remove old gasket and clean joint

369D290128-51 may be installed in lieu of

surfaces with P-D-680 dry cleaning

reworking 369D290128-31 cover assembly.

solvent (CM234) on a clean cloth.

(4). Rework cover, PN 369D290128-31 per

(2). Cut 1/8 inch (3.175 mm) thick pressure

illustration using fiberglass cloth and

sensitive tape (CM728) to 3/8 inch

resin. Laminate one layer of fiberglass

(9.525 mm) width.

cloth on top of cover and two layers on

bottom surface (Ref. Figure 802, detail

NOTE:

B).

D Note that the particle separator/aft inlet

fairing seal tape is not installed on the

(5). Drill two 0.250 inch (6.35 mm) diameter

bottom.

screw holes through cover to match

holes in PN 369D290128-11 fairing

D The inner seal tape is the mist eliminator

assembly.

joint seal.

(6). Install 369D290128-55 and -57 seals

(3). Cut tape to length, peel off backing and

on cover.

apply to surface.

(4). Ensure gasket tape is firmly attached

(7). Install reworked fairings (Ref. PLM

to surface.

Particle Separator Installation).

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MAINTENANCE MANUAL

2. Mist Eliminator Repair

(3). Using a 0.030 inch (0.762 mm) feeler

gage, check for gaps at the three

(1). The mist eliminator is a non-repairable

mounting bolt attach points. Install

all welded assembly except for the

shims in areas where gaps exceed 0.030

mounting bolts required for some

inch (0.762 mm) width per the next

installations. Repairs are limited to bolt

step.

repair or replacement.

(4). Bond an aluminum or fiberglass shim

NOTE:

thickness to the fairing that is equiva

lent to the gap.

D The following mist eliminator repair/re

placement items and, or kits are available

(a). Bond aluminum shims to the fairing

from Pall Land Marine (PLM) or through

with epoxy resin (CM504).

your local distributor.

(b). Laminate and bond fiberglass cloth

D AE-A224-1D2 Mist eliminator Assy.,

per Structural Repair Manual

complete.

procedures (CSP-DEF-6).

D AA-A224-1D2KF1 Repair kit, mist elimi

nator (nine mounting bolts).

4. Donaldson Particle Separator Repair

(369D Only)

(2). Remove mist eliminator assembly per

`Mist Eliminator Replacement'.

Consumable Materials

(3). Chase mounting bolt threads with a

(Ref. Section 91−00−00)

10-32 die, as required.

Item

Nomenclature

CM234

Solvent, dry-cleaning

(4). Remove mounting bolts from mist

CM503

Fiberglass repair kit

eliminator frame by pulling bolt aft

CM728

Tape, pressure sensitive

while unscrewing.

(5). Replace mounting bolts.

NOTE: Particle separator repairs are accom

plished per standard fiberglass repair meth

(6). Flatten an area 0.160-0.170 inch

ods using fiberglass repair kit (CM503). En

(4.064-4.318 mm) wide by 0.125 inch

sure that no potential for engine foreign

(3.175 mm) long, maximum, across the

object damage occurs as a result of filter re

first three to four threads adjacent to

pair.

the bolt shank to inhibit removal.

(1). Rebond loose or missing fiberglass

Particle Separator Alignment and Joint

attachment spacers.

Surface Repair (369D/E/FF)

(2). Rebond front and back wall to center

section seams as required.

Consumable Materials

(Ref. Section 91−00−00)

(3). Rebond manifold nozzle attachment

Item

Nomenclature

tube.

CM504

Epoxy resin with catalyst

(4). Patch repair or fill any other damaged

or cracked areas.

(1). Draw an outline of the particle separa

(5). Replace damaged vortex tubes.

tor on smooth, parallel surfaced, 1/2

NOTE: Up to five damaged vortex tubes may be

inch (12.7 mm) thick phenolic or close

temporarily blocked.

grained plywood. Cut template from

material. Drill mounting bolt holes.

(6). Install not more than five aluminum

patches over vortex tube outlet holes.

(2). Position template against engine air

Install patches with at least three

inlet fairing-to-filter mounting surface

mechanically expanded rivets.

and install three bolts and nuts finger

tight. Ensure template is secure and

(7). Replace worn or loose gasket tapes as

undistorted.

follows:

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(a). Remove tape debris. Wipe tape

NOTE:

contact surfaces with a clean cloth

D Installation of sealed fairings around the

and P-D-680 dry-cleaning solvent

particle separator to protect the engine

(CM234).

from FOD is required for early Donaldson

particle

separator

installations

369H90148-503 and -505 used on some

(b). Cut tape 0.380 inch (9.652 mm) wide

369D series helicopters.

from 0.125 inch (3.175 mm) thick

Y-3192-B material (CM728).

D Donaldson particle separator installa

tions are identified by the scavenge air ex

haust port on the left side of the aft inlet

(c). Install tape across the top and down

fairing.

right and left sides of the fairing

D Procedures cover fairing

kit,

contact area. Do not apply seal tape

PN 369D290140 and pressure switch,

across the bottom (Ref. Figure 803).

PN 369A8402-7 installation.

Install particle separator.

D PN 369A8402-3 pressure switch modifi

cations to -7 specifications using a Jensen

(8). Perform particle separator alignment

#800-174 kit are provided. Modification

procedures and the following steps.

of a -3 switch to a -7, or procurement and

installation of a -7 switch is mandatory

when auxiliary fairings are installed.

(a). Remove ejector-to-outlet duct rubber

sleeve. Use a straight edge to check

(1). Remove air inlet forward fairings.

for misalignment between the ejector

(2). Remove particle separator (Ref.

and outlet duct. Maximum allowed

Donaldson Particle Separator Remov

misalignment is 1/4 inch (6.35 mm).

al).

(3). Clean particle separator (Ref. Particle

(b). Install tapered shims between duct

Separator Cleaning).

and screen rubber rim to repair

ejector-to-outlet duct misalignment.

(4). Inspect particle separator (Ref. Donald

Use at least two attachment screws

son Particle Separator Inspection).

to retain shim.

(5). Repair unit (Ref. Donaldson Particle

Separator Repair).

NOTE: Existing screen and duct attachment

NOTE: 369D290140-5 and -7 supports and

screws are long enough to allow addition of

369D290140-11 and -12 fairing assemblies

1/4 inch (6.35 mm) thick shim.

may be manufactured using drawings pro

vided (Ref. Figure 806). Apply a coat of

(9). Install particle separator.

primer (CM318) after making the parts.

(6). Install LH fairings and seals as follows:

5. Donaldson Particle Separator Auxiliary

(a). Locate 369D290140-5 seal support

Fairings and Seals Installation

forward of aft fairing filter mounting

frame as indicated (Ref. Figure 805,

detail A and section B-B).

Consumable Materials

(b). Use -5 support as a guide and drill

(Ref. Section 91−00−00)

two rivet holes through fairing.

Item

Nomenclature

(c). Install support with two

CM234

Solvent, dry-cleaning

NAS1738B4-2 rivets.

CM318

Primer

(d). Install 369D290140-13 and -25 seals

CM430

Sealant, solvent resistant

on support (Ref. Figure 805, view

A-A and section B-B).

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MAINTENANCE MANUAL

(e). Position and mark 369D290140-11

(h). Install 369D290140-17 and -23 seals

fairing (Ref. Figure 805, view E-E).

on underside of 369H90151-41

Drill 0.250 inch (6.35 mm) diameter

fairing. Trim -23 seal to match

hole through -11 to match inlet

fairing contour (Ref. Figure 805, view

fairing existing nutplate.

A-A).

(f). Split grommet and install on wire

(8). Disconnect and remove 369A8402-3

and controls bundle (Ref. Figure 805,

pressure switch.

view E-E). Slip -11 fairing into

(a). Remove screws and separate switch

grommet groove.

halves. Remove diaphragm-magnet

(g). Trial fit 369D290140-11 fairing on

and return spring (Ref. Figure 807).

aft inlet fairing with washer and

(b). Clean parts with P-D-680 dry

screw. Remove fairing assembly.

cleaning solvent (CM234).

(h). Install 369D290140-17, -19 and -23

(c). Reassemble switch with new diaph

seals on underside of 369H90151-31

ragm-magnet and return spring per

fairing. Trim -19 and -23 seals to

illustration.

match fairing contour (Ref.

Figure 805, view A-A).

(d). Align screw holes, magnet-diaph

(7). Install RH fairings and seals as follows:

ragm, spring and switch halves and

assemble unit with screws. Lockwire

(a).

Locate 369D290140-7 seal support

screws.

forward of aft fairing filter mounting

frame as indicated (Ref. Figure 805,

(e). Install new name plate over existing

view A-A and section C-C).

name plate.

(b).

Use -5 support as a guide and drill

(9). Check pressure switch operation (Ref.

three rivet holes through fairing.

Air Pressure Sensing Switch Calibra

tion Check). Switch closing should occur

(c).

Install support with three

between 10.25-10.75 inches

NAS1738B4-2 rivets.

(26.035-27.305 cm) of water.

(d).

Install 369D290140-15 seal on

(10). Install pressure switch.

support (Ref. Figure 805, view A-A

and section C-C).

(11). Install particle separator (Ref. Donald

son Particle Separator Installation).

(e).

Position and mark 369D290140-12

fairing (Ref. Figure 805, view E-E).

(a). Install 369H90151-31 and -41

Drill 0.250 inch (6.35 mm) diameter

fairing halves with washers and

hole through -11 to match inlet

screws (Ref. Figure 805, view A-A).

fairing existing nutplate.

(b). Install 369D290140-11 and -12

(f).

Split grommet and install on wire

fairings with washers and screws

and controls bundle (Ref. Figure 805,

(Ref. Figure 805, view E-E).

view E-E). Slip -12 fairing into

(c). Apply sealing compound, RTV732

grommet groove.

(CM430) around all gaps between -11

(g).

Trial fit 369D290140-12 fairing on

and -12 fairings, grommets, wire

aft inlet fairing with washer and

bundles, aft fairing and mast fitting

screw. Remove fairing assembly.

(Ref. Figure 805, detail A).

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

-12 FAIRING ASSY

TRIM -12 FAIRING AS REQUIRED TO CLEAR

EXISTING STRUCTURE IN 369A3053

TYP. FOR INSTL. OF -11 FAIRING

-17 SEAL

-23 SEAL

369H90151-41

MOUNTING FRAME FOR

369H90152 FILTER AT

STA. 124.00

TRIM -19 AND -23 SEALS

TO MATCH CONTOURS

OF 369H90151 FAIRINGS

W.L. 67.00

3.31 IN.

B.L. 865 RN

(8.4074 CM)

369H90151-31

STA.

FAIRING

124.00

369A3053

FAIRING

SEE DETAIL A

-11 FAIRING ASSY

NAS173884-2 RIVET

-15 SEAL

-17 SEAL

(3 REQD)

DRILL 369A3053 TO

-7 SUPPORT

VIEW A - A

MATCH HOLES IN

SEAL ALL OPENINGS OR

SUPPORT

SECTION C - C

GAPS USING SILASTIC

ROTATED 90° CCW

NO. 732 OR EQUIV.

-11 FAIRING ASSY

MOUNTING FRAME FOR

369H90152 FILTER AT

STA. 124.00

W.L. 68.36

-13 SEAL

B.L. 8.70 LH

-25 SEAL

-5 SUPPORT

1.25 IN.

(3.175 CM)

APPLY SILASTIC NO. 732 OR

EQUIV. BETWEEN FLANGE

0.19 IN.

(4.826 MM)

OF FAIRING AND 369H3003

SEAL ALL OPENINGS OR

NAS173884-2 RIVET

GAPS USING SILASTIC

(3 REQD)

STA.

NO. 732 OR EQUIV.

DRILL 369A3053 TO MATCH

124.00

HOLES IN SUPPORT

SECTION B - B

DETAIL A

ROTATED 90° CCW

TYP. FOR INSTAL. OF -12 FAIRING

G71-1014-1A

Figure 805. Auxiliary Fairings and Seals Installation (Sheet 1 of 2)

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

-4 FAIRING FOR -12 ASSY (NOTE)

-3 FAIRING FOR -11 ASSY (NOTE)

MS20470AD2 RIVET (2)

-9 PLATE

-7 SUPPORT

0.19 IN.

(4.826 MM)

-15 SEAL

0.44 IN.

0.19 IN.

(11.176 MM)

(4.826 MM)

2.03 IN.

(5.1562 CM)

SECTION D - D

369H90151-41 FAIRING

ROTATED 180°

MS35489-19 GROMMET

SPLIT GROMMET APPROX.

AS SHOWN PRIOR TO INSTL.

369D23011

369H3003 FAIRING

-11 FAIRING ASSY

0.250 IN. (6.35 MM) DIA.

THRU -11 FAIRING ASSY

TO MATCH EXISTING

NUTPLATE LOCATIONS

VIEW E - E

ROTATED 90° CCW TYP. FOR

INSTL. OF -12 FAIRING ASSY

NOTE:

DRILL 0.063 IN. (1.6002 MM) DIA. HOLES IN

-3 AND -4 FAIRINGS TO MATCH HOLES IN

-9 PLATE (2 PLCS)

G71-1014-2A

Figure 805. Auxiliary Fairings and Seals Installation (Sheet 2 of 2)

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

3.51 IN.

(8.9154 CM)

0.098 IN. (2.4892 MM) DIA.

3.20 IN.

(3 PILOT HOLES)

(8.128 CM)

1.70 IN. (4.318 CM)

0.12 IN. (3.048 MM)

0.31 IN.

0.40 IN. (10.16 MM)

(7.874 MM)

0.80 IN. (20.32 MM)

0.43 IN. (10.922 MM)

0.68 IN. (17.272 MM)

0.37 IN.

5°

(9.398 MM)

(4 PLCS)

BEND UP X 0.09 IN. (2.286 MM) R

(2 PLCS)

-7 SUPPORT (FLAT PATTERN)

BEND UP X 0.09 IN. (2.286 MM) R

2.02 IN.

(5.1308 CM)

1.70 IN. (4.318 CM)

0.31 IN.

0.098 IN. (2.4892 MM) DIA.

(7.874 MM)

(2 PILOT HOLES)

6° 30' (4 PLCS)

0.12 IN. (3.048 MM)

0.35 IN. (8.89 MM)

0.77 IN. (19.558 MM)

0.23 IN. (5.842 MM)

0.31 IN. (7.874 MM)

0.80 IN. (20.32 MM)

0.40 IN. (10.16 MM)

0.37 IN. (9.398 MM)

3.50 IN.

(8.89 CM)

0.18 IN. (4.572 MM)

BEND DN X 0.09 IN. (2.286 MM) R

BEND UP X 0.09 IN. (2.286 MM) R

-5 SUPPORT (FLAT PATTERN)

2.03 IN.

(5.1562 CM)

0.19 IN.

0.31 IN.

(4.826 MM)

(7.874 MM)

0.44 IN.

0.75 IN. (19.05 MM)

(11.176 MM)

0.0635 IN (0.16129 MM)

(#52 DRILL)

-9 PLATE

G71-1015-1A

Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 1 of 2)

Page 812

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

30°

0.95 IN.

1.70 IN.

(24.13 MM)

(4.318 CM)

0.17 IN.

(4.318 MM)

1.56 IN.

(3.9624 CM)

0.93 IN.

(23.622 MM)

0.12 IN. (3.048 MM) R

0.81 IN.

2.00 IN.

(2 PLCS)

(20.574 MM)

(5.08 CM)

0.06 IN. (1.524 MM) R

(2 PLCS)

5.63 IN.

(14.3002 CM)

0.18 IN.

2.13 IN.

1.44 IN.

(4.572 MM)

(5.4102 CM)

0.40 IN.

(3.6576 CM)

0.31 IN.

(10.16 MM)

(7.781 MM)

1.06 IN. (2.6924 CM)

1.50 IN.

BEND DN 30° OPEN X

(3.81 CM)

0.12 IN. (3.048 MM) R

0.92 IN. (23.368 MM)

(2 PLCS)

0.12 IN. (3.048 MM) R

(2 PLCS)

30°

BEND DN X

0.12 IN. (3.048 MM) R

(2 PLCS)

-4 FAIRING (FLAT PATTERN) SHOWN

-3 OPP.

G71-1015-2A

Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 2 of 2)

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Revision 22

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

ENGINE AIR PARTICLE SEPARATOR

INITIAL INSTALLATION

1. Engine Air Particle Separator Initial

(10). On helicopters with cabin heat, remove

Installation

cabin heat control valve to facilitate

installing part number

369H90148-507, -519, or -527 particle

Consumable Materials

separators.

(Ref. Section 91−00−00)

Item

Nomenclature

Prevent engine FOD. Secure a

CAUTION

cover over the engine intake be

CM206

Chemical coating

fore working in or around plenum chamber.

CM318

Primer

(11). Remove engine air inlet forward fairing

and aft fairing access cover.

(1).

369H90148-519, -521, -527 and -529

particle separator installations are

(12). Remove plenum chamber access door.

covered by procedures in this section.

(13). Disconnect forward end of tail rotor

NOTE: Tag components as they are removed,

control rod at Sta. 95.00 bellcrank (Ref.

including attaching hardware. Protect loose

Sec. 67-20-10). Remove forward boot.

parts from damage, dirt or loss.

(14). Remove engine air cooling inlet screen.

(2). Ensure that battery switch and all

(15). Modify engine air cooling inlet screen

other helicopter switches are OFF.

(Ref. Figure 903, view B).

(3). Open crew compartment left floor

(16). Remove engine intake air inlet screen

access door and disconnect battery

(Ref. Sec. 71-10-00).

connector J108.

(17). Prepare airframe electrical ground

(4). Remove fairings from instrument panel

points per FAA publication, EA-

(Ref. Chap. 95).

AC43.13-1A and 2A.

(5). Remove rotor brake cover, where

(18). Using chemical film (CM206) treat

installed.

reworked areas as required and apply

primer (CM318) except on electrical

(6). Remove map case and interior trim

ground or bonding points.

panel (Ref. Sec. 25-30-00).

A. Filter Bypass Door and Aft Cable

(7). Remove map case cover upper left

(Ref. Figure 901)

support bracket.

(8). Remove transmission oil cooler inlet

Consumable Materials

duct (Ref. Sec. 63-21-00).

(Ref. Section 91−00−00)

Item

Nomenclature

NOTE: Installation of bleed air extraction el

CM410

Adhesive, epoxy (parts A & B)

bow, tee and hose with the engine in the he

licopter can be done; however, clearance is

minimal.

(1). Modify the plenum chamber access door

as follows:

(9). On helicopters without cabin heat,

remove engine to ease bleed air extrac

(2). Install clip and insert assembly on door

tion hardware installation prior to

with screws, washers and nuts.

installing part numbers

369H90148-509, -521, or -529 particle

(3). Install latch assemblies on door with

separators.

screws, washers and nuts.

Page 901

71-10-10

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

HINGE (2 PLCS)

FAIRING

0.63 IN. (16.002 MM)

SCREW

1.250 IN. (3.175 CM)

SCREW

WASHER

SCREW

NUT

WASHER

PLENUM CHAMBER ACCESS DOOR

LINK (2 REQD)

NUT

BOLT

NUT

WASHER

1.250 IN. (3.175 CM)

(NOTE 10)

BOLT

DOOR

NUT

WASHER

0.63 IN. (16.002 MM)

(NOTE 10)

PLATE

CLIP

DOOR

(NOTE 1)

1.00 IN. (2.54 CM)

PLATE (2 REQD)

REMOVE

A-A

SCREW

0.53 IN. (13.462 MM)

WASHER

NUT

NUTPLATE (4 PLCS)

CLIP

(NOTE 4)

RIVET (8 PLCS)

(NOTE 13)

SHIM

DOOR

HINGE

(NOTE 3)

(NOTE 9)

B-B

COVER

(NOTE 6)

RIVET (4 PLCS)

(NOTE 5)

0.62 IN. (15.748 MM) (TYP)

0.50 ±0.03 IN.

1.250 IN. (3.175 CM) (TYP)

(12.70 ±0.762 MM)

FIBERGLASS

CLOTH (1 PLY)

C-C

(NOTE 8)

FAIRING

0.50 ±0.03 IN. (12.70 ±0.762 MM)

0.56 ±0.03 IN. (14.224 ±0.762 MM)

GASKET

0.19 ±0.03 IN. (4.826 ±0.762 MM)

STA.

(NOTE 7)

STA.

(NOTE 3)

141.00

DOOR INSTALLATION

131.00

G71-1006-1A

Figure 901. Air Bypass Door Installation (Sheet 1 of 2)

Page 902

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

LATCH

CLIP

1.450 IN. (3.683 CM)

SHIM

(NOTE 1)

0.56 IN. (14.224 MM)

PLATE

LATCH

1.450 IN. (3.683 CM)

CLIP

0.56 IN.

(NOTE 1)

(14.224 MM)

1.62 IN. (4.1148 CM)

SHIM

0.68 IN. (17.373 MM)

(NOTE 12)

PLATE

DOOR

1.62 IN. (4.1148 CM)

0.68 IN. (17.373 MM)

(NOTE 12)

(REF)

D-D

STA.

136.00

GASKET

4.12 IN.

8.42 IN.

(10.4648 CM)

(21.3868 CM)

0.91 IN. (23.114 MM)

2.00 IN. (5.08 CM)

DOOR

CLIP

INSERT ASSY

E-E

NOTES:

DOOR PN 369A2099, 369H2087 AND 369D22087.

APPLY ONE PLY OF FIBERGLASS TO COVER-TRIMMED DOOR

INSTALL COVER. TRIM DOOR TO MATCH CONTOUR OF COVER SO AFT

EDGE PER DIMENSION SHOWN.

EDGE OF COVER OVERLAPS DOOR BY 0.19 IN. (4.826 MM) NOMINAL.

PEEL SHIM, AS REQUIRED, TO ALIGN DOOR AND FAIRING

REWORK NOT REQUIRED ON 369D290134 DOOR.

EXTERNAL SURFACES FLUSH WHEN DOOR IS LATCHED.

INSTALL MS20426A03-5 RIVETS FLUSH ON HINGE NEAR SIDE.

10. TIGHTEN NUT TO GET 0.005-0.015 IN. (0.127-0.381 MM) GAP

CENTER NUTPLATES ON EXISTING 0.196-0.210 IN. (4.9784-5.334 MM) DIA.

BETWEEN BOLT HEAD AND WASHER.

HOLES IN HINGE. POSITION NUTPLATES AS SHOWN ON FAR SIDE IF HINGE.

11. DIMENSION TO MATCH LATCH AND BE CENTERED WITHIN

DRILL FAIRING TO MATCH HOLE PATTERN IN COVER. INSTALL FOUR

0.060 IN. (1.524 MM) WITH CLIP.

MS20470AD-3 RIVETS.

12. DIMENSION TO MATCH CLIP AND BE CENTERED WITHIN 0.060 IN.

BOND COVER TO AFT FAIRING (REF. CSP-DEF-6).

(1.824 MM) WITH LATCH.

MAKE GASKET FROM DE41 CLOSED CELL NEOPRENE RUBBER. BOND TO

13. CHAMFER UPPER EDGE TO EASE DOOR LATCH ENGAGEMENT.

DOOR WITH ADHESIVE (CM418).

G71-1006-2A

Figure 901. Air Bypass Door Installation (Sheet 2 of 2)

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

DOOR CRANK

WASHER

EXISTING SCREWS,

CABLE TERMINAL

NUT

WASHERS, NUTS

AFT FAIRING

BRACKET

COTTER PIN

BOLT

CABLE

CONNECTION

NUT

FITTING

WASHER (2 PLCS)

BUSHING

PULLEY

NOTES:

(NOTE 3)

UPPER PULLEY

DRILL TWO 0.217-0.229 IN. (5.5118-5.8166 MM) DIAMETER HOLES.

INSTALLATION

COUNTERSINK 100° TO 0.43 IN. (10.922 MM) MINOR DIAMETER.

(TYP 2 PLCS)

FILL HOLES WITH ADHESIVE (CM410) OR EQUIVALENT.

PULLEYS TO BE IN ALIGNMENT WITHIN 0.13 IN. (3.302 MM).

G71-1007-2A

SHIM TO ALIGN CABLE WITH CABLE STOP WITHIN 0 060 IN (1 524 MM)

Figure 902. Aft Cable Installation (Sheet 2 of 2)

(4).

Attach links to latch and insert assem

stop into sleeve. Install washer and

bly with bolts, washers and nuts.

cable-stop jamnut.

Tighten nuts to get a 0.005-0.015 inch

(10).

Install sleeve assembly in bracket.

(0.127-0.381 mm) clearance between

Secure with washer and nut.

bolt-heads and washers.

(11).

Install door latch shims, clips, plates,

(5).

Install door hinge nut-plates with

screws, washers and nuts (Ref.

rivets.

Figure 901, view D-D).

(6).

Relocate upper right pulley bracket

(12).

Install bushing in lower pulley. Attach

mount holes (Ref. Figure 902, view B).

pulley assembly to bracket with shim

Drill 0.217-0.229 inch (5.5118-5.8166

between pulley and bracket. Install

mm) diameter holes. Countersink 100°

guard plate, spacer, screws and washers

to 0.430 inch (10.922 mm) diameter. Fill

over pulley. Attach the assembled

original holes with EA9314 epoxy

pulley bracket to fairing with screws,

adhesive (CM410) mixed per manufac

washers and existing nuts (Ref.

turers instructions.

Figure 902 detail C).

(7).

Install upper pulley brackets using

(13).

Install air bypass door on aft fairing

existing fasteners. Insert bushings in

with screws, washers and nuts.

two upper pulleys. Route cable assem

(14).

Screw fitting (Ref. Figure 902, detail E)

bly over pulleys.

onto cable terminal. Install fitting in

(8).

Install pulleys and cable assembly in

insert assembly crank arm with washer

brackets; install pulley bracket bolts,

and nut. Tighten nut to get a

washers and nuts.

0.005-0.015 inch (0.127-0.381 mm) gap

between crank and fitting head. Install

(9).

Install cable-stop bracket and shim

cotter pin. Bend cotter pin only enough

using existing fasteners. Thread cable

to keep it in place. Door rigging adjust

Page 905

71-10-10

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

ments will be required later to complete

(3). Cover saw cut with a single ply of glass

the installation.

cloth (Ref. Figure 901, detail C-C) and

per Structural Repair Manual, CSP-

(15).

Add or peel latch clip shims to align

DEF-6.

door and fairing external surfaces flush

C. Handle and Forward Cable Installation

with door closed and latched (Ref.

Figure 901).

(Ref. Figure 903)

(16).

Check pulley alignment. Pulleys shall

line up within 0.130 inch (3.302 mm) of

Consumable Materials

each other.

(Ref. Section 91−00−00)

Item

Nomenclature

(17).

Locate seal supports on fairing. Drill

CM318

Primer

fairing to match holes in supports.

Install rivets (Ref. Figure 904, detail A).

Special Tools

(Ref. Section 91−00−00)

(18).

Install seals on supports. Align LH

Item

Nomenclature

seals (Ref. Figure 904, detail A, sections

A-A and C-C).

ST2007

Rivnut installation speed header

ST2008

Rivnut keyway cutter

(19).

Remove coax, anti-ice and wire harness

cable support hardware, including clip

(Ref. Figure 904, views H-H and J-J).

(1).

Remove 369H6524-835 bracket (Ref.

Figure 903).

(20).

Locate and rivet ty-rap base in posi

(2).

Remove oil pressure sender tube

tion. Tie coax, anti-ice and wire

assembly from frame hole at canted

harness in one bundle. Secure bundle to

Sta. 78.50.

base with ty-raps.

(3).

Enlarge oil pressure sender tube

B. Cover Installation

bulkhead hole to 0.042 inch (1.0668

mm) diameter. Install grommet.

Consumable Materials

(4).

Modify map case or rotor brake cover

(Ref. Section 91−00−00)

(Ref. Figure 903, Sheet 3). Use fly-cut

Item

Nomenclature

ter as required.

CM418

Cement, epoxy

(5).

Attach control handle identification

decal to map case.

NOTE: 369D series helicopters equipped with

(6).

Drill and deburr rivet holes in angle,

engine inlet fairings other than part num

brackets and mount. Install brackets

bers 369A3053-505, -507 and -509 require

and mount.

modification of the air bypass door to clear

particle separator and the installation of a

(7).

Insert cable end into handle. Fit two

cover on the fairing (Ref. Figure 901, detail

retainer halves over swaged ball. Pull

B).

assembly back into handle to secure.

Install button plug.

(1). Use cover as a template and drill a

0.098 inch (2.4892 mm) diameter hole

(8).

Route cable assembly through bracket

in four places. Bond cover to fairing

and secure with nut and washers. Stack

using bonding adhesive (CM418).

washers as required to adjust handle

Install rivets.

protrusion into cabin.

(2). Trace aft edge of cover onto bypass door.

(9).

Trim fairing to get a 0.120 inch (3.048

Remove door and cut away material

mm) diameter gap between main rotor

0.190 inch (4.826 mm) forward of trace

mast and fairing (Ref. Figure 903, view

line.

F).

Page 906

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

(10).

Locate rivnut installation point (Ref.

D. Bleed Air System Installation (Helicopters

Figure 903, view A). Drill one

Without Cabin Heat)

0.250-0.256 inch (6.35-6.5024 mm)

diameter hole through pan. Use a

Consumable Materials

C-3576 key cutting tool (ST2008) to

(Ref. Section 91−00−00)

make a 0.062-0.065 inch (1.5748-1.651

Item

Nomenclature

mm) wide by 0.056-0.058 inch

CM112

Anti-seize compound high temperature

(1.4224-1.4732 mm) deep rivnut

keyway. Apply primer (CM318) to hole.

Install rivnut with a C-6000 speed

Compressor bleed air is hot

header (ST2007) while primer is wet.

CAUTION

enough to char tube identifica

tion tapes that may cause FOD. Remove

identification tapes from compressor bleed

(11).

Inspect rivnut installation. Rivnut

air tubes prior to installation.

length measured from upper surface of

head to blind end shall be between

NOTE:

0.365-0.415 inch (9.271-10.541 mm).

D Helicopters without Cabin Heating re

Rivnut shall be tight.

quire the installation of compressor bleed

air hardware on the engine for the par

(12).

Secure cable to rivnut with a clamp,

ticle separator scavenge air system.

washer and screw.

D Installation of bleed air extraction elbow,

tee and hose with the engine installed in

the helicopter can be done; however,

(13).

Install grommet in fairing (Ref.

clearance is minimal.

Figure 903, view D). Route cable

through grommet.

D Apply high temperature anti-seize com

pound (CM112) to male threads of all fit

tings prior to installation.

(14).

Locate and drill 0.390 inch (9.906 mm)

diameter hole through left fairing for

(1). Remove engine (Ref. Sec. 71-00).

pressure switch tube union (Ref.

(2). Continue with `Scavenge Air System

Figure 904, Sheet 1). Do not install

Installation'.

union at this time.

E. Bleed Air System Installation (Helicopters

With Cabin Heat)

(15).

Locate pressure switch support angle

position (Ref. Figure 904, Sheet 1). Drill

and deburr rivet holes. Install angle

Consumable Materials

with rivets. Do not install pressure

(Ref. Section 91−00−00)

switch at this time.

Item

Nomenclature

CM112

Anti-seize compound high temperature

NOTE: Ground connection (E45) requires mini

mum resistance to current flow for reliable

Compressor bleed air is hot

CAUTION

solenoid air valve operation.

enough to char tube identifica

tion tapes that may cause FOD. Remove

identification tapes from compressor bleed

(16). Prepare electrical ground (E45) stud

air tubes prior to installation.

installation per FAA publication,

EA-AC43.13-1A and 2A.

NOTE: Apply high temperature anti-seize

compound (CM112) to male threads of all fit

tings prior to installation.

(17). Install ground stud screw through

existing tool hole in stringer with

(1). Remove cabin heat control valve.

washers, jamnut and nut. Install decal

Remove existing control valve elbow

(Ref. Figure 907, detail B).

and O-ring.

Page 907

71-10-10

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

0.70 IN. (17.78 MM) DIA. HOLE

IN TRIM PANEL TO MATCH

TORQUE GAGE

CABLE FITTING

TUBE (REF)

OIL PRESSURE TUBE

ENLARGE HOLE TO 0.42 IN.

(10.668 MM) DIA.,

INSTALL GROMMET

FILTER BY-PASS CONTROL

PULL HANDLE FWD

OPTIONAL ROTOR

BRAKE HANDLE (REF)

HEATER CONTROL

CABLE

DECAL

0.22 IN. (5.588 MM) DIA.

HOLE IN TRIM PANEL TO

EXISTING RIVET

MATCH SHOCK MOUNT

LOCATION

0.096 IN. (2.4384 MM)

DIA. HOLE (8 PLCS)

CANTED STA. 78.50

0.22 IN. (5.588 MM)

TORQUE GAGE TUBE

RIVET EDGE

OPTIONAL ROTOR

(REF)

DISTANCE (TYP)

BRAKE COVER (REF)

MAP CASE OR OPTIONAL

ROTOR BRAKE COVER

GROMMET

WASHERS, AS REQUIRED, TO

ADJUST HANDLE PROTRUSION

FORWARD CABLE

MAP CASE OR OPTIONAL

ROTOR BRAKE COVER

OIL PRESSURE

SENDER TUBE (REF)

CABIN HEAT CONTROL

CABLE END FITTING

CABLE (REF)

NUT

RETAINER HALVES

0.44 IN.

(11.176 MM)

BRACKET

SHOCK MOUNT

0.73 IN. (18.542 MM)

0.096 IN. (2.4384 MM)

ANGLE

DIA. HOLE (2 PLCS)

RIVET (2 PLCS)

BYPASS DOOR

HANDLE

0.28 IN. (7.112 MM) RIVET EDGE

BUTTON

DISTANCE (TYP), PICK UP EXISTING

RIVET LOCATIONS

0.95 IN.

(24.13 MM)

HANDLE SUPPORT BRACKET INST

G71-1008-3A

Figure 903. Handle and Forward Cable Installation (Sheet 3 of 3)

Page 910

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

(2).

Install special three-port elbow and

(2). Attach one end of compressor bleed air

O-rings with existing fasteners. Torque

tube to special three-port elbow. Torque

three-port elbow flange self-locking

tube nut to 110 - 130 inch-pounds

nuts up to 18 inch-pounds (2.03 Nm).

(12.43 - 14.69 Nm).

Install cabin heat control valve. Torque

(3). Bolt solenoid valve to bracket. Attach

nuts to 20 - 25 inch-pounds (2.26 -

free end of bleed air tube assembly to

2.82 Nm).

solenoid valve. Torque tube nut to 110 -

(3).

Install universal elbow, O-ring and

130 inch-pounds (12.43 - 14.69 Nm).

jamnut on engine compressor scroll.

Do not scratch or gouge firewall

Torque jamnut to 145 - 155 inch-

CAUTION

surface when trimming heat

pounds (16.38 - 17.51 Nm) (Ref.

shield.

Figure 905).

(4).

Mark solenoid valve bracket position on

(4).

Install tee, jamnut and O-ring on

firewall heat shield pad. Remove

compressor diffuser duct. Torque tee

bracket, valve and tube. Cut an 0.125

jamnut to 285 - 315 inch-pounds

inch (3.175 mm) oversize opening

(32.20 - 35.59 Nm).

through heat shield pad for the valve

mounting bracket.

(5).

Install hose assembly between elbow

and tee. Torque hose nuts to 150 - 250

(5).

Drill and deburr valve bracket rivet

inch-pounds (16.95 - 28.25 Nm).

holes.

(6).

Install cover, spacer and gaskets on

(6).

Install bracket on firewall with six

special three-port elbow with bolts,

rivets.

washers and nuts.

(7).

Mount solenoid valve on bracket.

(7).

Loosely install special three-port elbow

Torque valve mounting bolts to 20 - 25

on canted firewall with bolts, washers

inch-pounds (2.26 - 2.82 Nm).

and nuts.

(8).

Install scavenge air tube between the

valve and elbow. Torque tube nuts 110 -

(8).

Install nut and O-ring on 0.750 inch

130 inch-pounds (12.43 - 14.69 Nm).

(19.05 mm) universal elbow and install

in three-port elbow. Torque three-port

(9).

Install elbow on scavenge air line

elbow flange self-locking nuts up to 18

support bracket (Ref. Figure 904, view

inch-pounds (2.03 Nm). Torque

G-G) with one washer on each side.

universal elbow jamnut 285 - 315

Install and torque jamnut to 120 - 150

inch-pounds (32.20 - 35.59 Nm).

inch-pounds (13.56 - 16.95 Nm).

(9).

Install engine (Ref. Sec. 71-00).

(10).

Trim away up to 0.050 inch (1.270 mm)

of bracket outboard edge to clear

(10).

Install tube assembly between firewall

intersecting angle and rivet heads.

mounted universal elbow and tee-fit

Install support assembly on shelf with

ting. Torque tube nuts to 460 - 500

washers and screws.

inch-pounds (51.97 - 56.49 Nm).

(11).

Locate scavenge air line elbow doubler

F. Scavenge Air System Installation

on plenum chamber bulkhead. Fasten

doubler to structure with rivets.

(Ref. Figure 905)

(12).

Install elbow, washer and nut on

(1). The scavenge air system consists of a

doubler. Torque elbow jamnut to 120 -

solenoid air valve, tubes, air pressure

150 inch-pounds (13.56 - 16.95 Nm).

switch, SCAV AIR circuit breaker

switch, AIR FILTER CLOGGED

(13).

Install upper scavenge air tube between

caution light, wiring, and attaching

elbows. Torque tube nuts 110 - 130

hardware.

inch-pounds (12.43 - 14.69 Nm).

Page 911

71-10-10

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

SEALING COMPOUND

(NOTE 6)

SEAL

(NOTE 7) SEAL

SUPPORT

RIVET (2 REQD)

0.84 IN.

TRIM

(21.336 MM)

SCREW,

(NOTE 8)

DETAIL

WASHER SCREW, WASHER

(NOTE 1)

SPACER

PARTICLE

SEPARATOR MIST ELIMINATOR

TAIL ROTOR SHAFT

TUNNEL (REF)

5.21 IN.

1.11 IN.

(13.2334 CM)

(2.8194 CM)

2.94-3.06 IN.

(7.4676-7.7724 CM)

1.36-1.48 IN.

(3.4544-3.7592 CM)

SCREEN

TAIL ROTOR PITCH

BYPASS

CONTROL ROD (REF)

FAIRING ASSY DOOR

GROMMET

CABLE

0.39 IN. (9.906 MM)

SCREW,

STA.

SEE

DIA. HOLE THRU

WASHER

127.00

131.00

DETAIL

FAIRING

(NOTE 2)

TOP VIEW

G71-1009-1A

Figure 904. Modifications and Installation (Sheet 1 of 4)

Page 912

Revision 22

71-10-10

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TAPE

(NOTE 9)

TUBE ASSY,

0.38 IN.

TORQUE TO

(9.652 MM)

25-35 IN. LB

(2.82-3.95 NM)

UNION, WASHERS,

JAMNUT, TORQUE

TO 65-80 IN. LB

(7.34-9.04 NM)

MIST ELIMINATOR

MOUNTING CLIPS

E- E

VIEW

MAST SUPPORT

FITTING (REF)

SUPPORT

SCREW,

TUBE ASSY

TRIM

WASHER

WASHER,

(NOTE 12)

SUPPORT

(NOTE 10)

SWITCH ASSY

WASHER,

NUT

ELBOW

ENGINE INLET

SCAVENGE AIR

ASSY (REF)

TUBE ASSY

SIDE VIEW

TRIM

(NOTE 11)

TUBE, TORQUE TO

G - G

110-130 IN. LB

VIEW

JAMNUT, TORQUE TO

FWD

(12.43-14.69 NM)

120-150 IN. LB

(13.56-16.95 NM)

INLET FAIRING

(REF)

MAST SUPPORT

(REF)

SCREW,

CLIP

CLAMPS

(REMOVE)

STA.

127.00

BASE,

RIVET

INLET

MIST ELIMINATOR

BASE,

0.38-0.50 IN.

FAIRING

ACCESS PANEL

RIVET

(9.652-12.7 MM

(REF)

STA.

MAST SUPPORT

(INSTALL)

127.00

F- F

VIEW

H- H

VIEW

J - J

(REF)

VIEW

(RH SIDE ONLY)

G71-1009-3A

Figure 904. Modifications and Installation (Sheet 3 of 4)

Page 914

Revision 22

71-10-10

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

FAIRING

JAMNUT, TORQUE

DOUBLER

TO 240-280 IN. LB

(27.12-31.64 NM)

FLAPPER VALVE

PARTICLE SEPARATOR

ELBOW, FITTING,

O-RING, NUT

EJECTOR

TUBE, TORQUE

VIEW LOOKING AFT

TO 110-130 IN. LB

(12.43-14.69 NM)

NUTPLATES, RIVETS

RIVET (2 PLCS)

0.16 IN.

(6 PLCS), FAR SIDE

FAIRING

(NOTE 14)

(4.064 MM)

(NOTE 13)

DUCT

1.13 IN. (2.8702 CM)

0.33 IN.

(8.382 MM)

0.63 IN.

(16.002 MM)

(TYP)

DOUBLER

SCREW, WASHER

RIVET

DOUBLER

RIVET

(6 PLCS)

(NOTE 15)

(NOTE 16)

(NOTE 15)

0.63-0.69 IN.

(16.002-17.526 MM)

VIEW

k-k

VIEW

L-l

LOOKING INBOARD

G71-1009-4A

Figure 904. Modifications and Installation (Sheet 4 of 4)

Page 915

71-10-10

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Legend (Ref. Figure 904)

0.250 IN. (6.35 MM) DIAMETER HOLE THROUGH

IF INSTALLING MIST ELIMINATOR; APPLY 0.125 IN.

FAIRINGS TO MATCH EXISTING NUT−PLATE

(3.175 MM) THICK BY 0.380 IN. (9.652 MM) WIDE

LOCATION.

PRESSURE SENSITIVE TAPE (CM728) OR

0.250 IN. (6.35 MM) DIAMETER HOLE THROUGH

EQUIVALENT TO PARTICLE SEPARATOR PRIOR TO

INSTALLATION.

FAIRING TO MATCH LOWER FAIRING ASSEMBLY

10.

USE EXISTING NUT−PLATES.

NUT−PLATE LOCATION; LEFT AND RIGHT SIDES.

11.

TRIM SUPPORT AS REQUIRED TO CLEAR RIVET

INSTALL SEAL AFTER SUPPORT INSTALLATION.

HEADS.

DRILL 0.250 IN. (6.35 MM) DIAMETER HOLE

12.

TRIM OUTBOARD EDGE OF SUPPORT 0.050 IN.

THROUGH FAIRING ASSEMBLY TO MATCH EXISTING

(1.270 MM), MAXIMUM, TO CLEAR ANGLE.

NUT−PLATE LOCATION.

13.

DRILL 0.217−0.229 IN. (5.5118−5.8166 MM) DIAMETER

SPLIT GROMMET ON TANGENT SHOWN PRIOR TO

SCREW HOLES TO MATCH DOUBLER HOLES.

INSTALLATION.

14.

EQUALLY SPACE RIVETS BETWEEN NUT−PLATES.

APPLY SEALING COMPOUND (CM430) TO ALL

15.

PICK UP EXISTING RIVET LOCATIONS.

OPENINGS AND GAPS.

16.

CUT HOLE THROUGH AFT FAIRING TO MATCH

ALIGN BOTTOM EDGES OF SEALS.

DOUBLER. BOND DOUBLER TO EXTERIOR FAIRING

TRIM LOWER FAIRING AS REQUIRED TO CLEAR AFT

SURFACE WITH ADHESIVE (CM410) PER

FAIRING STRUCTURE.

MANUFACTURERS INSTRUCTIONS.

(14).

Install tee on solenoid air valve. Install

(2).

Install varistor across connector P206

cap on tee.

pins A and B (Ref. Figure 103, detail A).

Solder (CM815) connections per

(15).

Install tube assembly between solenoid

standard shop practices.

valve tee and elbow. Torque tube nuts

110 - 130 inch-pounds (12.43 - 14.69

(3).

Connect wire P17D20N to solenoid

Nm).

valve connector P206 pin B and ground

lug E45 with washers and nut.

(16).

Install scavenge air tube clamp support

bracket, spacer, clamp, screws, wash

(4).

Solder wire P16C20 to connector P206,

ers, and nuts (Ref. Figure 905, detail

pin A.

C).

(5).

Route solenoid air valve wire harness

(17).

Clamp tube assembly to air duct with

through airframe (Ref. Figure 907).

clamps, screw, washers and nut (Ref.

(6).

Install wire harness, part number

Figure 905, detail B).

369A4163 as follows:

G. Solenoid Valve and Pressure Switch Wire

(7).

Solder varistor between pins A and B of

Harness Installation

connector P206 (Ref. Figure 103, detail

A).

Consumable Materials

(8).

Route wire harness through airframe

(Ref. Section 91−00−00)

Item

Nomenclature

(Ref. Figure 907).

CM815

Solder

(9).

Connect wire P17A20N to ground lug

E45.

NOTE: If using prefabricated wire harness,

(10).

Splice solenoid valve wire P16D20 to

part number 369A4163, go to step (6). If not

airframe wire P16C20.

using prefabricated wire harness, proceed

as follows:

(11).

Determine correct pressure switch wire

length. Trim wires as required.

(1). Do not clamp wiring until routing and

connections are complete. Install wires

(12).

Install knife splice halves on pressure

per FAA publication, EA-AC43.13-1A

switch pigtails. Install knife splice

and 2A. Where possible, route added

halves on airframe wires P16G22 and

wiring along existing wire harness.

P16H22N.

Page 916

Revision 22

71-10-10

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

NUT

CLAMP

TO EJECTOR

NOZZLE (REF)

WASHER

TUBE ASSY

DOUBLER

CLAMP

(NOTE 1)

TUBE ASSY, TORQUE

TO 110-130 IN. LB

SCREW

(12.43-14.69 NM)

(NOTE 4)

BOLT

COVER

RIVET

WASHER

(6 PLCS)

NUT, TORQUE TO

STRINGER

GASKET

120-150 IN. LB

SPACER

(13.56-16.95 NM)

GASKET

WIRE HARNESS

WASHER

CLAMP

TRANSMISSION

BOLT

OIL COOLING

WASHER

HOSE ASSY, TORQUE

DUCT (REF)

NUT, TORQUE

TUBE ASSY,

TO 150-250 IN. LB

TO 20-25 IN. LB

TORQUE TO

(16.95-28.25 NM)

(2.26-2.82 NM)

110-130 IN. LB

(12.43-14.69 NM)

ELBOW

(NOTE 2)

ELBOW

SOLENOID

BRACKET

BOLT

VALVE

ASSY

NUT, TORQUE TO

WASHER

(NOTE 2)

145-155 IN. LB

(16.38-17.51 NM)

5.65 IN. (14.351 CM)

O-RING

ENGINE

COMPRESSOR

NUT

SCROLL (REF)

TEE

WASHER

NUT, TORQUE

TO 18 IN. LB

(2.03 NM)

TEE

SPACER

BRACKET

CAP

HEAT SHIELD

(NOTE 3)

PAD (NOTE 2)

NUT

TUBE, TORQUE TO

NUT, TORQUE TO

460-500 IN. LB

285-315 IN. LB

WASHER

NUT, TORQUE TO

(51.97-56.49 NM)

(32.20-35.59 NM)

285-315 IN. LB

O-RING

SCREW

(32.20-35.59 NM)

ELBOW

O-RING

SCREW

CLAMP

G71-1010A

Figure 905. Scavenge Air Equipment Installation

Page 917

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Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Legend (Ref. Figure 905)

1. LOCATE DOUBLER ON PLENUM CHAMBER WALL AT

2. BOLT SOLENOID VALVE TO MOUNTING BRACKET.

THE INTERSECTIONS OF STA. 126.25 AND W/L 52.50.

ATTACH TUBE BETWEEN VALVE AND ELBOW TO

CENTER DOUBLER ON A POINT 1.50 IN. (3.81 CM)

LOCATE VALVE ASSEMBLY ON FIREWALL. TRIM

BELOW PLENUM CHAMBER ANGLED FLOOR PAN.

AWAY HEAT SHIELD PAD BENEATH BRACKET PRIOR

DRILL ONE 0.578 IN. (14.6812 MM) DIAMETER HOLE

TO RIVETING BRACKET TO FIREWALL.

THROUGH CENTER. DRILL SIX EQUALLY SPACED

3. USE EXISTING STRINGER TOOLING HOLE.

RIVET HOLES AROUND DOUBLER. MAINTAIN A 0.220

4. HAND FORM AS REQUIRED TO CLEAR

IN. (5.588 MM) MINIMUM RIVET EDGE DISTANCE.

STRUCTURES.

NOTE: Ensure electrical continuity and mini

(5). Cut hole in aft engine inlet fairing to

mum resistance between ground wire

match hole in doubler.

P16H22N and airframe.

(6). Bond rib in position (Ref. Figure 906).

(13). Connect either switch pigtail to air

(7). Drill six holes through fairing to match

frame wire P16G22. Connect remaining

holes in doubler, Install nut-plates and

lead to airframe ground wire P16H22N.

rivets (Ref. Figure 904, view K-K).

(14). Install clamps and ty-raps.

(8). Install ejector duct (Ref. Figure 904,

view L-L) with screws and washers.

(15). Refer to Instrument Panel Modifica

tions; T-Pedestal or Slimline Panel

I. Particle Separator Installation

Modification for crew compartment

wiring information.

Consumable Materials

(16). Vacuum all debris from work area.

(Ref. Section 91−00−00)

Item

Nomenclature

(17). Inspect all tube connections for correct

CM106

Fluorocarbon dry lubricant

torque values. Inspect all components

CM112

Anti-seize compound high temperature

and attaching hardware for correct

CM234

Solvent, dry-cleaning

installation and security.

CM405

Adhesive

H. Ejector Duct Doubler and Rib Installation

CM425

Sealing compound

CM430

Sealant, solvent resistant

Consumable Materials

(Ref. Section 91−00−00)

(1). Position particle separator inside

Item

Nomenclature

engine air inlet aft fairing. Coat

CM418

Cement, epoxy

mounting bolt threads with anti-seize

compound (CM112).

NOTE: Doubler is required for all installations.

(a). Temporarily attach separator to

Rib installation is required for helicopters

mount boss with bolts and washers.

not equipped with 369A3053-505, -507, or

Stack washers under right bolt head

-509 engine inlet fairing assemblies.

as necessary. Check fit.

(1). Drill out required rivets (Ref.

NOTE: Do not grind mast support fitting un

Figure 904, view K-K and Figure 906).

less particle separator cannot be installed

due to interference with fitting.

(2). Locate and bond doubler to fairing

exterior with adhesive (CM418).

(2). Remove particle separator and grind

material from corner of mast support

(3). Install rivets through doubler and

fitting (Ref. Figure 903, detail C).

fairing.

(3). Drill 0.250 inch (6.35 mm) diameter

(4). Back-drill from inside of engine inlet

holes through horizontal fairings to

fairing through existing rivet holes and

match auxiliary fairing nut-plates (Ref.

doubler.

Figure 904, Sheet 1).

Page 918

Revision 22

71-10-10

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

PARTICLE SEPARATOR

TRIM FIBERGLASS

MOUNTING FRAME

CLOTH TO PREVENT

OVERLAP INTO

1.19-1.44 IN.

0.50-0.75 IN.

COUNTERBORE

(3.0226-3.6576 CM)

(12.7-19.05 MM)

RIVET, WASHER

(2 PLCS)

0.75 IN.

(19.05 MM)

0.63-0.88 IN.

(16.002-22.352 MM)

OVERLAP

(NOTE 4)

RIVET,

1.03-1.25 IN.

WASHER

RIB

(2.6162-3.175 CM)

(7 PLCS)

(NOTE 1, 2)

FAIRING

FIBERGLASS CLOTH

DOUBLER

(NOTE 3)

1.13-1.25 IN.

(FAR SIDE)

(2.8702-3.175 CM)

EJECTOR DUCT OPENING

LOOKING OUTBOARD

NOTES:

RIB INSTALLATION ONLY REQUIRED FOR HELICOPTERS NOT EQUIPPED

WITH 369A3053-505, -507 OR -509 ENGINE INLET FAIRING ASSEMBLY.

INSTALL RIB AND FIBERGLASS CLOTH PRIOR TO INSTALLING NUTPLATES

AND NUTPLATE RIVETS.

BOND RIB TO FAIRING WITH ADHESIVE (CM410) PER MANUFACTURERS

INSTRUCTIONS.

APPLY A MINIMUM OF TWO PLIES OF FIBERGLASS CLOTH (CM501) WITH

RESIN (CM506) OR EQUIVALENT PER MANUFACTURERS INSTRUCTIONS.

G71-1011A

FIBERGLASS CLOTH TO OVERLAP HOLE EDGE 0 09 0 19 IN (2 286 4 826 MM)

Figure 906. Ejector Duct Doubler Installation

Page 919

71-10-10

Revision 22

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

(4). Drill 0.250 inch (6.35 mm) diameter

(11).

Install particle separator with washers

holes through auxiliary fairing vertical

and bolts.

plates to match aft inlet fairing nut-

(12).

Install scavenge air supply tube

plates (Ref. Figure 904, view D-D).

between ejector nozzle and shelf

NOTE: Do not install auxiliary fairings at this

mounted elbows. Torque ejector nozzle

time.

elbow jamnut 240 - 280 inch-pounds

(27.12 - 31.64 Nm). Torque tube nuts

(5). If installation does not include mist

110 - 130 inch-pounds (12.43 - 14.69

eliminator, install bolts and washers in

Nm).

the three lowest particle separator mist

(13).

Modify two grommets as shown (Ref.

eliminator attachment holes. Torque

Figure 904, view D-D). Install grom

bolts 20 - 25 inch-pounds (2.26 - 2.82

mets over left and right wire bundles.

Nm).

Insert left and right auxiliary fairing

(6). If installation includes mist eliminator,

assemblies into grommet grooves.

wipe rear surfaces of particle separator

Install screws and washers through

clean with dry cleaning solvent

auxiliary fairing vertical plates.

(CM234) on a clean cloth. Wipe dry.

(14).

Install pressure switch sensing tube

union on left fairing with one washer on

(7). Attach 0.125 inch (3.175 mm) thick by

each side of fairing. Torque union

0.380 inch (9.652 mm) wide pressure

jamnut 65 - 80 inch- pounds (7.34 -

sensitive seal tape to particle separator

9.04 Nm).

aft surface around mist eliminator

frame and fairing frame contact areas

(15).

Attach tail rotor control rod cover, if so

(Ref. Figure 904, view E-E).

equipped, to left fairing with existing

fasteners. Complete all fairing installa

(8). Install rubber seal (Ref. Figure 904,

tions.

section B-B) on the forward lower shelf

edge of the particle separator as

(16).

Install pressure switch. Torque pres

follows:

sure switch jamnut 65 - 80 inch-

pounds (7.34 - 9.04 Nm).

(a). Apply one heavy brush coat of

(17).

Install upper and lower pressure switch

adhesive (CM405) to seal and particle

tubes. Torque tube nuts to 25 - 35

separator joint surfaces. Let surfaces

inch-pounds (2.82 - 3.95 Nm).

dry 15 minutes.

(18).

Seal all gaps around auxiliary fairing

(b). Apply a second coat of adhesive.

installations with sealant (CM430)

Immediately press seal in place.

(Ref. Figure 904, view D-D).

Allow assembly to air dry a minimum

of eight hours.

(19).

Use existing screw to attach clip to

structure (Ref. Figure 903, detail E).

NOTE: Do not install mist eliminator support

Install clamp on cable with clip, screw,

channels if helicopter is not equipped with a

washer and nut.

mist eliminator access panel on top of the aft

fairing (Ref. Figure 904, view F-F).

(20).

Install cable return spring and retain

ers (Ref. Figure 903, detail D). Secure

(9). Install mist eliminator support chan

spring assembly with cable connector.

nels on particle separator lower aft face

(21).

Close and latch air bypass door.

with screws (Ref. Figure 904, view

Connect forward and aft cable sections.

E-E).

Distance between center of forward

(10). Install scavenge air line special elbow,

cable swaged ball terminal and aft face

O-ring and nut on particle separator

of fairing should be between 6.56 and

ejector assembly. Do not torque elbow

6.80 inches (16.662 and 17.272 cm) with

jamnut at this time (Ref. Figure 904,

no cable slack (Ref. Figure 903 detail

Sheet 4).

D).

Page 921

71-10-10

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(22).

On helicopters without mist eliminator

rod forward boot free length to between

access panel, remove air bypass door.

7.130 and 7.250 inches (18.1102 and

Spray 15 milliliters, total, of engine oil

18.4150 cm). Secure with ty-raps.

on mist eliminator front and rear

J. Instrument Panel Modifications;

surfaces. Insert mist eliminator,

T−Pedestal

forward face up, through bypass door

opening and move to engage nine mist

(1).

Do not install clamps or ty-raps on

eliminator mount bolts with particle

wiring until wiring installation is

separator. Start all bolts by hand.

complete. Install wires per FAA

Torque bolts to 20 - 25 inch-pounds

publication, EA-AC43.13-1A and 2A.

(2.82 - 3.95 Nm).

Where possible, route added wiring

along existing wire bundles.

(23).

Install door gasket on aft fairing with

adhesive (CM405) per manufacturers

(2).

Remove plug button from SCAV AIR

instructions.

switch panel hole.

(24).

For operation below 40°F (4.5°C), spray

(3).

Connect wire P514D20 between pin 1 of

door gasket and door edge with fluoro

SCAV AIR (CB15) circuit breaker

carbon dry lubricant (CM106).

switch and pin 1 of POS LT circuit

breaker switch CB119 (Ref.

(25).

Install air bypass door.

Figure 103).

(26).

Rig bypass door (Ref. Air Bypass Door

(4).

Connect wire P16MA20 (stowed inside

Rigging).

console) to pin 2 of CB15.

(27).

Apply sealing compound (CM425) to

(5).

Install SCAV AIR circuit breaker switch

door cable fitting cotter pin (Ref.

in panel.

Figure 902, detail E).

(6).

Remove third from right dummy block

(28).

On helicopters equipped with mist

from caution and warning light panel.

eliminator access panel disengage two

(7).

Connect stowed wires P514C20 to pin 2

1/4-turn fasteners and remove access

of light assembly and wire P514B20 to

panel (Ref. Figure 904, view F-F).

pin C.

(29).

Use locking pliers to pull while turning

(8).

Install AIR FILTER CLOGGED caution

nine mounting bolts, if so equipped, out

light assembly.

of mist eliminator frame. Discard bolts.

K. Slimline Panel Modification

(30).

Pass mist eliminator through access

opening into engagement with lower

(1). Use switch and light subpanel bracket

support channels. Hold mist eliminator

as a template. Locate and drill a 0.219

against particle separator and install

inch (5.5626 mm) diameter hole

access panel. Lock panel fasteners.

through instrument panel hood and left

fairing above existing hole.

(31).

Inspect mist eliminator installation

through bypass door opening. Check

(2). Cut a 0.50 inch (12.70 mm) wide slot,

that mist eliminator is firmly in

2.98 inches (7.5692 cm) long with full

position against particle separator.

radius at forward end in instrument

Adjust as required.

panel left fairing.

(32).

Remove mist eliminator and spray a

(3). On helicopters equipped with

total of 15 milliliters of clean engine oil

369H90022 anti-ice fuel filter (airframe

on front and rear surfaces. Reinstall

filter) installation; remove plug buttons

mist eliminator.

from AIR FILTER CLOGGED and

SCAV AIR subpanel positions. Wire and

(33).

Clamp tail rotor control pedals in

install switch and light (Ref.

mid-position. Adjust tail rotor control

Figure 103).

Page 922

Revision 22

71-10-10

HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 28